Plant:-….5S Maint TGW /Learnings cum RC Establishment : Why-Why Analysis for Machines Major B/D.

(Mandatory for To be used for all critical parts (imported) changes , B/D more than a shift and/or Top 1 Major B/D in Hrs analysis ) (Maint/WW-001/00)

Machine No.: Haeing Furnace Process Heating ICA Dt. 27.01.22 Doc No.:- GMT-FR-11A

Physical Dubble Bar Idea / Actions and Status:

observation by (Eg. Design change /Drg change / Spare Part increase /PM freq.increase /PM c/point add)
Maint. :-
Sl. Actions Resp Tgt Status
No

Immediate / Re Set Sensor Position 1 Re Set Sensor Position Sudheer 27.01. ok

Corrective Action 22
Taken (By Maint)
2 PM Plan Change Half Yearly to Quaterly Ravendr 03.02. ok
a 22

RC establishment

Why 1 Dubble Bar

Why 2 Walking Beam Not Fully Forward EFFECTIVENESS MONITORING

Why 3 Walking Beam Bush Wear & Tear MONTH 1

Why 4 MONTH 2

Why 5 MONTH 3

RC:- Walking Beam Bush Wear & Tear STANDARDIZATION

Sign & Dt. Maint Members :- Maint. Chief:

Plant:-….5S Maint TGW /Learnings cum RC Establishment : Why-Why Analysis for Machines Major B/D.
(Mandatory for To be used for all critical parts (imported) changes , B/D more than a shift and/or Top 1 Major B/D in Hrs analysis ) (Maint/WW-001/00)

Machine No.: Process ICA Dt. Doc No.:- GMT-FR-11A

Physical Idea / Actions and Status:

observation by (Eg. Design change /Drg change / Spare Part increase /PM freq.increase /PM c/point add)
Maint. :-
Sl. Actions Resp Tgt Status
No

Immediate /
Corrective Action
Taken (By Maint)

RC establishment

Why 1

Why 2 EFFECTIVENESS MONITORING

Why 3 MONTH 1

Why 4 MONTH 2

Why 5 MONTH 3

RC:- STANDARDIZATION

Sign & Dt. Maint Members :- Maint. Chief:

Plant:-….5S Maint TGW /Learnings cum RC Establishment : Why-Why Analysis for Machines Major B/D.
(Mandatory for To be used for all critical parts (imported) changes , B/D more than a shift and/or Top 1 Major B/D in Hrs analysis ) (Maint/WW-001/00)

Machine No.: Shotpeening 1st Process ICA Dt. 09.03.22 Doc No.:- GMT-FR-11A

Physical Bearing Brocken in Rotary Screan Idea / Actions and Status:

observation by (Eg. Design change /Drg change / Spare Part increase /PM freq.increase /PM c/point add)
Maint. :-
Sl. Actions Resp Tgt Status
No

Immediate / Replace Bearing F 211 1 Replace Bearing F 211 Sudheer 09.03. Ok

Corrective Action Added Rubber Sheet 22
Taken (By Maint)
2 Added PM Plan

RC establishment

Why 1 Bearing Brocken in Rotary Screan

Why 2 Dust Powder Gone In Side EFFECTIVENESS MONITORING

Why 3 MONTH 1 ok

Why 4 MONTH 2 ok

Why 5 MONTH 3

RC:- Dust Powder Gone In Side STANDARDIZATION

Sign & Dt. Maint Members :- Maint. Chief:

Plant:-….5S Maint TGW /Learnings cum RC Establishment : Why-Why Analysis for Machines Major B/D.
(Mandatory for To be used for all critical parts (imported) changes , B/D more than a shift and/or Top 1 Major B/D in Hrs analysis ) (Maint/WW-001/00)

Machine No.: Shotpeening # 1 Process Shotpeening ICA Dt. 22.03.22 Doc No.:- GMT-FR-11A
23.03.22

Physical Spring Stuck in Transfer conveyor & Damage Idea / Actions and Status:
observation by (Eg. Design change /Drg change / Spare Part increase /PM freq.increase /PM c/point add)
Maint. :-
Sl. Actions Resp Tgt Status
No

Immediate / Remove Spring Form Transfar Metal 1 Remove Spring From Metal Conveyor Sudheer 22.03. ok
Corrective Action Conveyor 22
Taken (By Maint)
2 Replace Conveyor Metal To Rubber Sudheer 03.04. ok
22

RC establishment

Why 1 Spring Damage of Transfar Conveyor

Why 2 Springs Stuck Metal conveyor & Machine EFFECTIVENESS MONITORING

Body.

Why 3 Metal Conveyor MONTH 1

Why 4 MONTH 2

Why 5 MONTH 3

RC:- Metal Conveyor STANDARDIZATION

Sign & Dt. Maint Members :- Maint. Chief:

Plant:-….5S Maint TGW /Learnings cum RC Establishment : Why-Why Analysis for Machines Major B/D.
(Mandatory for To be used for all critical parts (imported) changes , B/D more than a shift and/or Top 1 Major B/D in Hrs analysis ) (Maint/WW-001/00)

Machine No.: Quench Tank Process Quenching ICA Dt. 08.04.22 Doc No.:- GMT-FR-11A
(Spring)

Physical Conveyor Motor Overload Trip Idea / Actions and Status:

observation by (Eg. Design change /Drg change / Spare Part increase /PM freq.increase /PM c/point add)
Maint. :-
Sl. Actions Resp Tgt Status
No

Immediate / Replace Break Relay 1 Replace Relay Haider 08.04. ok

Corrective Action 22
Taken (By Maint)
2 Replace Relay High Rating Haider 23.04. ok
22

RC establishment

Why 1 Conveyor Motor Overload Trip

Why 2 Motor Current to high EFFECTIVENESS MONITORING

Why 3 Motor Break Not Properly Reliease MONTH 1

Why 4 Relay Contect Carbonize MONTH 2

Why 5 Relay Contect Rating Less MONTH 3

RC:- Relay Contect Rating Less STANDARDIZATION

Sign & Dt. Maint Members :- Maint. Chief:

Plant:-….5S Maint TGW /Learnings cum RC Establishment : Why-Why Analysis for Machines Major B/D.
(Mandatory for To be used for all critical parts (imported) changes , B/D more than a shift and/or Top 1 Major B/D in Hrs analysis ) (Maint/WW-001/00)

Machine No.: TransPorter Process Maint Shop ICA Dt. 02.05.22 Doc No.:- GMT-FR-11A

Physical Transporter Not run in Auto Mode Idea / Actions and Status:
observation by (Eg. Design change /Drg change / Spare Part increase /PM freq.increase /PM c/point add)
Maint. :-
Sl. Actions Resp Tgt Status
No

Immediate / Replace Moduel 1 Replace PLC Moduel Ravendr 02.05. ok

Corrective Action a 22
Taken (By Maint)
2 Added Relay For Stop Current Leckage Ravinde 22.05. ok
r 22

RC establishment

Why 1 Transporter Not run in Auto Mode

Why 2 PLC Input Failure EFFECTIVENESS MONITORING

Why 3 Leckage Current MONTH 1

Why 4 MONTH 2

Why 5 MONTH 3

RC:- Leckage Current STANDARDIZATION

Sign & Dt. Maint Members :- Maint. Chief:

Plant:-….5S Maint TGW /Learnings cum RC Establishment : Why-Why Analysis for Machines Major B/D.
(Mandatory for To be used for all critical parts (imported) changes , B/D more than a shift and/or Top 1 Major B/D in Hrs analysis ) (Maint/WW-001/00)

Machine No.: Process ICA Dt. Doc No.:- GMT-FR-11A

Physical Idea / Actions and Status:

observation by (Eg. Design change /Drg change / Spare Part increase /PM freq.increase /PM c/point add)
Maint. :-
Sl. Actions Resp Tgt Status
No

Immediate /
Corrective Action
Taken (By Maint)

RC establishment

Why 1

Why 2 EFFECTIVENESS MONITORING

Why 3 MONTH 1

Why 4 MONTH 2

Why 5 MONTH 3

RC:- STANDARDIZATION

Sign & Dt. Maint Members :- Maint. Chief:

Plant:-….5S Maint TGW /Learnings cum RC Establishment : Why-Why Analysis for Machines Major B/D.
(Mandatory for To be used for all critical parts (imported) changes , B/D more than a shift and/or Top 1 Major B/D in Hrs analysis ) (Maint/WW-001/00)

Machine No.: Paint Shop Process Transporter ICA Dt. 25.07.2022 Doc No.:- GMT-FR-11A

Physical Transporter Out of track Idea / Actions and Status:

observation by (Eg. Design change /Drg change / Spare Part increase /PM freq.increase /PM c/point add)
Maint. :-
Sl. Actions Resp Tgt Status
No

Immediate / Re Setting Transporter 1 Replace Dubble Side Suport Wheel Sudheer 01.08. ok
Corrective Action 2022
Taken (By Maint)

RC establishment

Why 1 Transporter Out of track

Why 2 Transporter Wheel Wear & Tear EFFECTIVENESS MONITORING

Why 3 Transporter Wheel Single Suport. MONTH 1

Why 4 MONTH 2

Why 5 MONTH 3

RC:- Transporter Wheel Single Suport. STANDARDIZATION

Sign & Dt. Maint Members :- Maint. Chief: